Installation Instructions for C/1/9 Cable Troughs

Transcription

1 Installation Instructions for C/1/9 Cable Troughs December 2015 Rev 2.1

2 1. Introduction This document is meant to gives basic guidance on the installation of the Ecotrough range of cable troughs. Ecotrough is a cable trough system that is in effect a surface trench that protects and provides continuous accessibility to the signal cables. Signal cables can exit and enter the cable trough system from either side of the trough. The typical Ecotrough installation requires a trench of minimum width to provide free access to both sides of the trough while maintaining 200mm (8 inches) of ballast and sub-ballast alongside and below the trough to allow free passage of storm water from around and below the trough. The maximum ballast size should not exceed 19mm (0.75 inches). Fill material should not be placed on frozen ground and should be tamped. The cable trough should be placed so that the lowermost part of the knockout is 25mm (1 inch) higher than the surrounding ground or ballast surface. Where the cable trough run is installed in an existing ballast section, it is important that when the cable troughs are installed that the installer restores the ballast to its original dressed configuration. It is important that the installer does not foul the ballast configuration with unsuitable materials. It is recognized that under normal conditions the installation of cable troughs should be straight forward if the basic guidelines are followed. However, ground conditions and circumstances may vary, and in this event additional guidance and/or supplementary instructions may be required. In these circumstances, any queries should be addressed to the overall scheme designer. It should be noted that this document is not a comprehensive guide to cover every eventuality associated with cable trough installation, and, it is expected that the installation work is delivered under the control of a suitably qualified and experienced person. Within the rest of this document the term Ecotrough has the same meaning as the generic term cable troughs.

3 2. Delivery of Goods Ecotrough s are generally delivered on 24 ton articulated curtain sided vehicles. If access is restricted, and you require a smaller vehicle, or you require a Moffett or Hiab with the delivery then please advise customer support in Affresol. Tel Each delivery will include a laminated sheet showing the breakdown of the type of Ecotrough and quantities, and order details Your Ecotrough order will be delivered to site on pallets for a pre-arranged time. When you receive the delivery, you must check to ensure that: The delivery note matches the goods being delivered. All Ecotrough product are free from damage. Damage is this sense is deemed to be cracked or broken units. Ecotrough units have a gelcoat external covering for ease of extraction from moulds. This gelcoat has no relevance to the integrity of the product. There may on occasions small chips of gelcoat missing on the outside of the trough or lid, this is not a problem and is nothing to be concerned about. Any damage must be brought to the attention of the driver of the delivery vehicle and noted on the delivery note. It is worth noting that parts of the delivery may overhang the edge of the pallet. It is advisable to check these overhang areas as they may have been damaged in transit. Please be aware of the Health and Safety issues during unloading. It may be that sections of the Ecotrough cable run may need to be sealed from the elements. In this event, the delivery note will show a quantity of Sticksall. This is a bonding/sealant that works well with Ecotrough and can be used under water or any other adverse weather conditions. Please ensure the quantity on delivery note matches what is being delivered.

4 3. Handling & Storage 3.1 Handling Unloading and handling on site must be undertaken carefully to avoid damage to product. Care should be taken to avoid impact damage to the edges of each trough unit and lids. Troughs should be offloaded using a telehandler or fork lift truck relevant to load weight. 3.2 Storage As the Ecotrough products are waterproof there are no special storage instructions However, the products should be kept free from soil, mud, or any other substances which may damage the trough or trough lid or interfere with the jointing process. The pallets should be unloaded as close to the intended installation site as possible. An appropriate flat area should be cleared for unloading. Try to avoid handballing the units any long distance! We recommend that the pallets should be stored on firm, level ground with full width timber bearers positioned approximately 100mm from each end, beneath the bottom row. Troughs may be stacked up to 3 high. Additional timber bearers may be required to support longer lengths of trough. Lids may be stacked up to six high in a similar manner.

5 4. Excavation & Preparation 4.1 Preparing the trench. It is important that you ensure that there is a consistent supporting base for the trough. Raised hard or soft spots in the trench should be removed and replaced with bedding or selected ballast. You should have been advised of the details of the required trench depth and width. This is generally a standard for each type of trough. If you have any concerns about the ground conditions (particularly if the ground appears to be unstable) and/or loading, then consult your supervisor. Any groundwater should be kept below the bottom of the trough. The supervisor will advise on the best course of action. This may be specific precautions or involvement of another third party. Remember Watch out for trackside hazards/obstacles, Follow Manual Handling Guidelines. Stay safe at all times! 4.2 Ballast Specification The maximum railway ballast size should not exceed 19mm (0.75 inches). Fill material should not be placed on frozen ground and should be tamped. Good ballast must be: the correct size and shape hard resistant to crushing and abrasion resistant to water wet attrition value angular will interlock to form a stable matrix to support the track & troughing, but allow free drainage Detailed in Network Rail specification NR/SP/TRK/006 Please remember, the ballast system is a key element on the network. Degradation of the ballast comes from several sources not least of which is introduction of non-specification materials. This can be, as the result of the formation of cable trenches which has been know, to introduce both non-specification materials and the ingress of vegetable matter. It has been proven that there is a strong correlation between ballast problems and problems in maintaining good track geometry (track quality)

6 5. Installation of the Ecotroughs Note. 1. Prepare trench formation to required level and lay ballast base 2. Position trough to required line and level. 3. Position adjacent trough and if required apply Stickall sealant between units before butting them together. 4. Place ballast haunching to sides of trough as installation proceeds. 5. Continue installation procedure until full length of troughing has been installed. 6. Carefully place suitable backfill ballast material around the trough to re-form required finished levels. 7. Install adjacent construction as required. Transitions in horizontal and vertical alignment can be achieved by Tee and Curve units. Various sizes and configurations are available. Contact Affresol Ltd for more information. 6. Trough Lid Placement As a general rule of thumb, the lids will sit flush on the trough sides and need no further interaction. As the lids and troughs are the same dimension as concrete they can be interchanged on an as required basis. In trafficked locations, the lids should be seated on a 3mm bed of Butyl tape. This will act as a retainer & bedding strip, and it will reduce noise from vibration. There are occasions where some lids are subject to slewing by commercial vehicles. In this event, the lids may require fixing to the trough. This can be achieved by Butyl Tape or an approved epoxy mortar mix. Affresol Ltd (December 2015) Affresol Ltd reserve the right to alter any specifications given in accordance with its policy of continuous product development. All rights reserved.